M2HB CALIBER - DTIC · 2015-05-26 · BLANK FIRING ATTACHMENTS .«. ' ... caliber .50 Machine Guns. In response to this need for a WESS, BFA to be used on the M2HB Machine Gun were

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EVALUATION OF TWO BLANK FIRING ATTACHMENTS .«.

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ABSTRACT

Firing tests were conducted using an M2HB Caliber .50 Machine Gun equipped with blank firing attachments (BFA) fabricated at Ft. Benning and Ft. Carson. Two BFA of each design were tested. Both designs operate on the muzzle booster principle. Three lots of blank ammunition were tested and one lot of M33 ball ammunition was fired to provide a base line for comparison of weapon mechanism performance. All of the existing blank ammunition including those lots tested were loaded in 1943-44 or in 1953. Because of its age and the way it was packed and stored the performance of individual rounds has deteriorated and varies widely down to refusal to fire. Although the erratic ammunition performance prevented quantitative accuracy in evaluation of test results the data did provide a basis for engineering evaluation and the recommendation that a coordinated program of ammunition and BFA development be considered for early implementation.

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CONTENTS

TITLE PAGE PAGE

ABSTRACT . i

CONTENTS ii

REPORT DOCUMENTATION iii - iv

BACKGROUND [ ' ■ 1

OBJECTIVES 2

SCOPE OF PROGRAM 3-4

SUMMARY OF RESULTS 5

SECTION I TIME-DISPLACEMENT RECORDS 6-13

SECTION II ENDURANCE FIRING 14-18

SECTION III ENERGY TRANSFER 19-21

ANALYSIS OF RESULTS 22-23

CONCLUSIONS 24

RECOMMENDATIONS 25

RECOMMENDED DEVELOPMENT PROGRAM 26

APPENDIX A RECOMMENDED DEVELOPMENT PROGRAM 27 - 35

APPENDIX B PHOTOGRAPHS 36-48

APPENDIX C INSPECTION REPORTS 49-59

APPENDIX D AMMUNITION PERFORMANCE S SELECTION 60 - 64

DISTRIBUTION LIST 65 - 66

ii

SECURITY CLASSIFICATION OF THIS PAGE (When Data Entered)

REPORT DOCUMENTATION PAGE READ INSTRUCTIONS BEFORE COMPLETING FORM

TTREPORT NUMBER

R-TR-76-022

2. 30VT ACCESSION NO. 3. RECIPIENT'S CATALOG NUMBER

4. TITLE fand Sub(/(/e;

EVALUATION OF TWO BLANK FIRING ATTACHMENTS FOR THE M2HB CALIBER .50 MACHINE GUN

5. TYPE OF REPORT & PERIOD COVERED

Final, Sept 75 - June 76 6. PERFORMING ORG. REPORT NUMBER

7. AUTHORC«J 8. CONTRACT OR GRANT NUMBERfsJ

Roy F. Schwegler

9. PERFORMING ORGANIZATION NAME AND ADDRESS

GEN Thomas J. Rodman Laboratory (SARRI-LS-P) Rock Island Arsenal Rnrk TQlanH, Tl 61201

10. PROGRAM ELEMENT, PROJECT, TASK AREA a WORK UNIT NUMBERS

11. CONTROLLING OFFICE NAME AND ADDRESS 12. REPORT DATE

GEN Thomas J. Rodman Laboratory (SARRI-LS-P) Rock Island Arsenal Rock Island, IL 61201

13. NUMBER OF PAGES

14. MONITORING AGENCY NAME a ADDRESSCJf d/ffer«n( Irom Controlling Office) 15. SECURITY CLASS, fo/ (his report;

15«. DECLASSIFI CATION/DOWN GRADING SCHEDULE

16. DISTRIBUTION STATEMENT fo/(his ReporO

Approved for public release; distribution unlimited

17. DISTRIBUTION STATEMENT (of the abstract entered In Block 30, II different from Report)

18. SUPPLEMENTARY NOTES

19. KEY WORDS (Continue on reverse aide If neceaaary and Identify by block number)

BFA BLANK FIRING ATTACHMENT CAL .50 BLANK FIRING ATTACHMENT M2HB MACHINE GUN WEAPON EMISSION SIMULATOR SYSTEM

WESS MUZZLE EROSION

20. ABSTRACT fContynuo on reverae aide It neceaaary and identify by block number)

Firing tests were condu with blank firing attac Two BFA of each design booster principle. Thr M33 ball ammunition was mechanism performance. lots tested were loaded way it was packed and s

cted using an M2HB Caliber .50 Machine Gun equipped hments (BFA) fabricated at Ft. Benning and Ft. Carson, were tested. Both designs operate on the muzzle ee lots of blank ammunition were tested and one lot of fired to provide a base line for comparison of weapon All of the existing blank ammunition including those in 1943-44 or in 1953. Because of its age and the

tored the performance of individual rounds has

DD ,^ FORM AN 73 1473 EDITION OF 1 NOV 65 IS OBSOLETE

iii - iv SECURITY CLASSIFICATION OF THIS PAGE (When Data EnteredJ

SECURITY CLASSIFICATION OF THIS PAOCOnian Dmtm Entmnd)

deteriorated and varies widely down to refusal to fire. Although the erratic ammunition performance prevented quantitative accuracy in evaluation of test results the data did provide a basis for engineering evaluation and a recommendation that a coordinated program of ammunition and BFA development be considered for early implementation.

SECURITY CLASSIFICATION OF THIS PAGEn>k«i Balm Bnlmnd)

BACKGROUND

Currently, there is no widely available blank firing attachment (BFA) for the M2 Heavy Barrel Caliber .50 Machine Gun, nor for the M85 Caliber ,50 Machine Gun. Neither is there a current caliber .50 round of blank ammunition. Existing blank ammunition is overage (1942-44 and 1953 manufacture) made from obsolete unavailable components and does not perform reliably nor consistantly. Thus there is no way to simulate the firing of caliber .50 Machine Guns in field training exercises and two of the primary anti-personnel/anti-light vehicle/anti-air weapons cannot be employed in tactical training.

Given the requirement to use the weapons in engagement simulation systems such a REALTRAIN and MILES, a suitable weapon emission simulation system (WESS) is urgently required to provide a signature from the position of the firing weapon. The BFA can serve as that WESS for the caliber .50 Machine Guns.

In response to this need for a WESS, BFA to be used on the M2HB Machine Gun were fabricated at Ft. Benning and Ft. Carson. Both of these BFA are based on the muzzle booster concept and differ primarily in attachment means and structural detail. These devices received consid-^ erable testing at APG(l) and Ft. Benning(2) leading the Project Manager for Training Devices (PM-TRADE) to become concerned that prolonged use of these BFA would result in permanent damage or accellerated wear to the weapon. Subsequently, PM-TRADE tasked SARRI-LS-C to evaluate the effect of these BFA on weapon life and recommend a program to develop a BFA and round of ammunition. This report summarizes the result of this evaluation.

(1) ENGINEER DESIGN TEST (SAFETY EVALUATION) OF TRAINING DEVICE, BLANK FIRING, ADAPTER FOR CALIBER .50 M2 MACHINE GUN, TECOM PROJECT NO 1-WE-B23- 000-009, REPORT NO APG-MT-4729

(2) OPERATIONAL FEASIBILITY TEST OF CALIBER .50 BLANK FIRING ADAPTER, TRADOC PROJECT NO 8-WE-418-BFA-601. USAIB PROJECT NO 3472

OBJECTIVES

There are two objectives to this test program and evaluation:

1. Determine the nature and extent of physical damage or excessive wear to the M2 Heavy Barrel, Caliber .50 Machine Gun which may be expected through prolonged use of Blank Firing Attachments (BFA) similar to those fabricated at Ft. Benning and Ft. Carson.

2. Recommend a development program which will lead to a Weapon Emission Simulation System (WESS) using the M2HB and/or M85 Machine Gun(s) for field training exercises.

SCOPE OF PROGRAM

Four blank firing attachments, two of the Ft. Carson design and two of the Ft. Benning design, were selected for testing. Three lots of blank ammunition, LC-L-95903, LC-L-12035, and TW-L-18052 were used for test firing. M33 Ball Ammunition from Lot No. LC-L-l-lie was used to establish performance baseline values.

The tests were conducted using a single receiver modified to permit taking time-displacement (T-D) records of the bolt travel. Two sets of parts (bolt sets) consisting of one bolt assembly, one lock block, and one accelerator were assigned to each BFA design. One of these bolt sets was used during the firing for the T-D records and the other bolt set was used when conducting the endurance test. Time displacement records were taken at 0°F, ambient and at 1250F.

Following the completion of the time-displacement records the parts sets and blank firing attachments were replaced and an endurance test was conducted on each type of blank firing attachment.

Each endurance test was scheduled to consist of 9,900 rounds with periodic inspections of the bolt sets approximately every 300 rounds to detect the onset and extent of wear or failure. These inspections were alternated with one blank firing attachment and associated bolt set being inspected while the other blank firing attachment and bolt set underwent a 300 round firing cycle.

A single machine gun barrel was used throughout the series of time- displacement and endurance tests until 13,261 rounds of blank ammunition had been fired through it. At that point muzzle errosion had progressed to the extent that the weapon would not cycle. The barrel and barrel extension were replaced to permit completion of the endurance test on the Ft. Carson blank firing attachment. The remaining 1,650 rounds were fired and upon inspection the muzzle cylinder was discovered to have developed a bulge.

Data taken from the time-displacement records was summarized and evaluated against weapon performance when firing M33 Ball Ammunition. Inspection reports on the bolt sets and periodic measurements made on the muzzle diameter were reviewed to detect wear or errosion trends.

All endurance testing was conducted on the premise that the basic performance of the blank firing attachment-ammunition combination would approximate as closely as possible weapon performance values obtained with M33 Ball ammunition. No attempt was made to deliberately overload either the weapon or the blank firing attachment.

Endurance testing using the Ft. Carson blank firing attachment was conducted with ammunition Lot No. LC-L-95903 since time-displacement records indicated this ammunition induced bolt energy in the order of 90 percent to 95 percent of the energy induced by M33 Ball Ammunition.

In the case of the Ft. Benning blank firing attachment only Lot No. TW-18052 would cycle the weapon in a reliable manner. Thus inspite of the fact that time-displacement records indicated induced bolt energy was over 20 percent in excess of that induced by M33 Ball Ammunition, the endurance test was attempted using TW-18052 ammunition for lack of an alternative. This test was terminated after 4,530 rounds because increasingly poor ignition performance of the available ammunition prevented continuity of weapon cycling and stressing and significant temperatures were not being achieved. In addition, unburned propellant in the weapon and surrounding it posed an increasing safety hazard.

SUmARY OF RESULTS

The data as collected is far too voluminous to be included in this report. Instead, summaries germane to the immediate objectives are included which present the data in reduced form to facilitate the readers comprehension.

Section I is a concise summary of pertinent dynamic values for the combined mass of the barrel, barrel extension and bolt assembly before the bolt is unlocked from the barrel extension and also the pertinent dynamic values for the mass of the bolt assembly only following unlocking. The maximum kinetic energy of the unlocked bolt is then stated as a percentage of the maximum kinetic energy of the bolt as observed when firing the M33 round of ball ammunition.

Section II is a Table recording the problems encountered when firing the endurance test with references to the Appendix for substantiating data on component wear.

Section III is intended to provide insight into the transfer of barrel - barrel extension kinetic energy to the bolt assembly after unlocking. An energy transfer efficiency is calculated for the energy transfer. The observed trend of this efficiency to rise as initial velocity increases is believed to be due to added energy from increased residual pressures in the bore and muzzle cylinder rather than any change in the efficiency of the mechanical acceleration.

SUmARY OF RESULTS

SECTION I

SUMMARY OF TIME-DISPLACEMENT RECORDS

ANALYSIS OF TIME-DISPLACEf€NT RECORDS Nomenclature

Symbol

VI

V2

El

E2

Units

inch/second

inch/second

lb-inch

lb-inch

Description

Maximum Velocity of Barrel, Barrel Extension and Bolt Assembly before unlocking of the bolt during Recoil.

Maximum Velocity of Bolt in Recoil.

Maximum Energy of Barrel, Barrel Extension and Bolt Assembly before unlocking of the bolt during Recoil.

Maximum Energy of Bolt in Recoil.

Mean of the distribution of Values.

Standard Deviation of the distribution of values.

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SUmARY OF RESULTS

SECTION II

SUMMARY OF ENDURANCE FIRING RECORDS

14

ENDURANCE FIRING RECORD: FT. CARSON BLANK FIRING ATTACHMENT

IB USING T40 BLANK LOT NUMBER LC-L-95903 TABLE 7

Rds on Blank Firing Attachment

No. of Underpowered Rds

1-330 8

331-660 4

661-990 3

991-1320 0

1321-1650 0

1651-1980 3

1981-2310 0

2311-2640 0

2641-2970 0

2971-3300 0

3301-3630 10

3631-3960 2

3961-4290 13

4291-4620 17

4621-4950 28

4951-5280 13

5281-5610 22

5611-5940 27

5941-6270 n 6271-6600 2

6601-6980 0

6931-7260 1

7261-7590 0

15

Remarks

Chamber cleaned

Chamber cleaned

Chamber cleaned

Chamber cleaned

TABLE 7 Cont.

Rds on Blank Firing Attachment

No. of Underpowered Rds

7591-7920 0

7921-8250 330

8251-8580 15

8581-8910 12

8911-9240 3

9241-9570 14

9571-9900 117

Remarks

Weapon operated manually- short recoil barrel & barrel extension changed

Muzzle cap bulged

16

ENDURANCE FIRING RECORD: FT. BENNING BLANK FIRING ATTACHMENT

2B USING Ml BLANK LOT NUMBER TW-L-18052 TABLE 8

Rds on Blank No of Firing Attachment Underpowered Rds Remarks

1-330 14

331-660 9 Chamber cleaned


991-1320 7 . Chamber cleaned

1321-1650 7


1981-2310 10 .

2311-2640 0

2641-2970 TO

2971-3300 4

3301-3630 5

3631-3960 15 . Loose propellant in chamber Chamber cleaned

3961-4290 44 Loose propellant in chamber Chamber cleaned

4291-4530 53 Loose propellant in chamber- Chamber cleaned. Propellant flash in receiver. Firing terminated per SARRI-LS-C

17

"«-^^

BARREL DIAMETER MEASUREMENTS: M2HB CAL. .50 MACHINEGUN BLANK FIRING

ATTACHMENT TEST TABLE 9

*Barrel Diameter, inches

No. of Rds Fired

1.501 X 1.501 0

1.499 X 1.500 100

1.497 X 1.498 158

1.500 X 1.502 258

1.497 X 1.501 316

1.498 X 1.500 426

1.498 X 1.499 537

1.497 X 1.497 586

1.492 X 1.502 2766

1.496 X 1.498 4746

1.496 X 1.498 6751

1.495 X 1.493 8731

1.489 X 1.493 11,281

1.488 X 1.489 13,261

Remarks

Initial Measurement

Low Temperature test (0°F)

High temperature test (125°F)

Ambient temperature test (70°F)

Functioning & endurance test

*Measurements shown were taken in the vertical and horizontal planes, respectively, at approximately 0.5 inches from face of muzzle

18

SUNFIARY OF RESULTS

SECTION III

SUMMARY OF AVAILABLE ENERGY TRANSFERRED

AFTER UNLOCKING

19

ENERGY TRANSFER EFFICIEflCY

Rationale: The firing cycle of the M2HB Caliber .50 Machine Gun starts with firing of the round in the chamber. Recoil and muzzle booster action then cause the barrel, barrel extension and bolt assembly to move toward the rear reaching a velocity, V-j. After traveling a short distance to the rear, the bolt assembly is unlocked and released from the barrel extension and barrel. At about this point, the mechanical accelerator is engaged. The action of the accelerator stops the motion of the barrel and barrel extension and increases the velocity of the bolt assembly to a maximum, Vo. The kinetic energy of the bolt assembly moves the bolt further to trie rear, thereby compressing the drive spring and storing energy with which to complete the firing cycle.

1. The kinetic energy of the bolt assembly at maximum recoil velocity, V2, is a measure of the ability of the weapon mechanism to complete its firing cycle.

2. The kinetic energy of the combined barrel, barrel extension and bolt assembly at velocity V], is a measure of the ability of the blank firing attachment to impart energy into the weapon mechanism.

3. The efficiency with which energy given up by the barrel and barrel extenstion is transferred through the accelerator to the bolt assembly is a measure of accelerator performance and an indicator of the existence of excessive loads on the breech lock and/or the accelerator.

The Energy Transfer Efficiency, Erg, is calculated from Time-Displacement data as follows:

ENERGY GAINED BY BOLT ^ ^QQ

ÊB " ENERGY LOST BY BARREL AND EXTENSION

4.5 X V^ - V^

E^B= -^""-^ ^ I ^ X 100

ÊB

386.4 X 2

30.4 X V^ -< 385.4 X 2

14.8 X V^ -A

20

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21

AMLYSIS OF RESULTS

Both the Ft. Carson and Ft. Benning BFA are of the muzzle booster type; thus, this evaluation is limited to examining the performance of the M2HB Machine Gun Caliber .50 when powered by the muzzle booster type BFA.

Analysis of Ft. Carson time-displacement recordings reveal:

1. The Ft. Carson BFA firing blank ammunition from Lot Nos LC-L- 95903 and LC-L-12035 generated bolt velocities and energies representative of those generated by firing M33 Ball ammunition.

2. The Ft. Carson BFA was severely overpowered (42% average excess) with blank ammunition from Lot No. TW 18052.

Based on the above analysis, and inspection of the physical condition of the available ammunition. Lot No LC-L-95903 was selected over LC-L-12035 to conduct the scheduled endurance test of 9900 rounds.

Analysis of Ft. Benning BFA time-displacement records revealed that the weapon was:

1. Underpowered with blank ammunition Lot Nos LC-L-95903 and LC-L- 12035.

2. Significantly overpowered (20% average excess) with blank ammunition Lot No TW-18052.

An attempt was made to conduct an endurance firing test of 9900 rounds using the TW-18052 ammunition. This test was abandoned after 4530 rounds when it became apparent that due to the erratic ignition characteristics of the TW-18052 blank ammunition, it was not possible to maintain sus- tained firing long enough to explore heat disbursing capacity of the muzzle booster in a manner that could be compared with tests of the Ft. Carson BFA for evaluation of barrel muzzle errosion. Furthermore, there were substantial quantities of unburned powder which accumulated in the receiver and periodically flashed causing concern for the gunner's safety.

Inspection of the barrel and muzzle booster revealed that serious errosion and heat checking of the muzzle could be expected after 6,000 to 8,000 rounds had been fired and that prolonged firing caused the muzzle booster to bulge from the effects of the heat and pressure. From this, the following conclusions are drawn:

22

•i-

1. In their present form both BFA designs lack sufficient heat dis- persion capability for safe firing of prolonged bursts.

2. Some means for preventing barrel muzzle errosion and heat checking is required especially if the weapon is to be used for accurate firing of ball ammunition on short notice without replacing the barrel.

Periodic inspection of the bolt, lock block and accelerator disclosed no excessive wear on these components. This fact coupled with data taken from time-displacement records was taken to indicate that a muzzle booster type BFA with matched blank ammunition could be expected to operate the weapon without unusual wear or damage to the mechanism for well in excess of 10,000 rounds, but that the muzzle of the barrel will be critically erroded and damaged.

Both the Ft. Carson and the Ft. Benning BFA blow gas and fine solid particles back into the gunner's face to varying degrees depending on clearance between the barrel and muzzle booster bore and the number of rounds fired since the BFA was cleaned. The gunners received no mark nor discernable injury from the gas or solid particles but the impact was distracting, uncomfortable, and poses a potential hazard.

23

CONCLUSIONS

The following conclusions can be drawn from this program:

1. Use of the Ft.Benning and Ft Carson BFA's can result in serious heat checking and erosion of the barrel muzzle. Parts wear does not exceed that caused by firing the M33 Ball ammunition if the blank ammunition is suitably matched to the BFA.

2. The Ft Carson BFA, when used with blank ammunition from Lot No TW-18052, severely overpowers (over 42%) the weapon mechanism to the detriment df the weapon life and safety.

3. The Ft Benning BFA, when used with blank ammunition from Lot No TW-18052, significantly overpowers (over 20%) the weapon mechanism and most probably reduces weapon life.

4. Both the Ft Benning and Ft Carson BFA's lack adequate heat dissipation capacity to safely sustain prolonged firing.

5. The present BFA designs permit excessive amounts of gas and combustion particles to be blown into the gunner's face.

6. The integral discriminator/mounting feature of the Ft Carson's BFA:

a. Effectively prevents accidental feeding of ball and tracer ammunition.

b. Provides good support and alignment for the muzzle cyclinder of the BFA.

c. Can provide minimal interference with weapon mounting/installations.

7. The eccentric support to the muzzle cylinder on the Ft Benning BFA causes pronounced flexing and whipping of the restraining rods which could lead to early fatigue failure.

8. The performance of existing ammunition varies so much both between lots and within lots that a new round must be developed in conjunction with BFA development to create a weapon/BFA/ammunition system whose performance will meet all training requirements with consistancy and safety.

24

z^

RECOmENDATIONS 1. Future development of a "muzzle booster" type blank firing attachment (BFA) should:

a. Improve heat dissipation of the muzzle cylinder. b. Protect the barrel muzzle from heat checking, wear and erosion. c. Improve safety factors under all operating conditions. d. Eliminate gas and particle leakage in the direction of the gunner.

2. Alternative concepts to the "muzzle booster" type BFA should be designed and tested, especially "floating chamber" devices.

3. Special attention should be given to development of BFA concepts which promote:

a. Accurate control of the volume of gas under pressure. b. Accurate control of pressure release timing at all temperatures. c. Adequate safety factors for all components especially those parts

subject to heat and pressure during firing. d. Maximum protection from safety hazards arising from accumulations

of unburned powder. e. Maximum protection from safety hazards arising from "han^-fire"

rounds. f. Maximum protection from accidental loading and firing of a ball round.

4. A common round of caliber..50 blank ammunition should be developed for use with all caliber .50 BFA.

5. New blank ammunition should be manufactured to exacting tolerances and spec- ifications to assure consistant reliable performance.

6. The caliber .50 blank round shall have approximately the same profile as a ball pound and be capable of "push through" stripping and feeding as well as "pull-push" feeding common to the M2HB weapon.

7. All BFA designs shall operate their specific weapons so that the dynamics of the weapon mechanism when firing a coninon blank round will approximately equal but not exceed dynamic values generated when firing standard ball ammunition.

8. Development of a BFA/Ammunition system for the M2HB and the M85 Machine Guns should be conducted simultaneously in accordance with the program and schedule discussed on the following page and detailed in Appendix A.

25

RECOmENDED DEVELOPMENT PROGRAM

Objective: The Recommended Development Program will develop a single round of blank caliber .50 armiunition and two separate Blank Firing Attachments (BFA), one specifically designed for use on the M2HB Machine Gun and the other BFA specifically designed for use on the M85 Machine Gun.

Technical Approach: The Recommended Technical Approach is to conduct a coordinated program of simultaneous development to produce the BFA's and the ammunition in accordance with the development plan entitled "Blank Firing Attachments (BFA) and Blank Ammunition Product Improvement Program for M2HB Caliber .50 Machine Guns Using a Common Round of Blank Ammunition" and the accompanying schedule and events shown in the appendix.

26

lb' A

APPENDIX A

RECOmENDED DEVELOPMENT PROGRAM

27

BLANK FIRING ATTACHMENTS (BFA) AND BLANK AMMUNITION PRODUCT IMPROVEMENT PROGRAM FOR M2HB AND M85 CALIBER .50 MACHINE GUNS

USING A COMMON ROUND OF BLANK AMMUNITION

Appropriation: Ammunition and Training Device.

System/End Item: Caliber .50 Blank Firing Attachment and Ammunition for use with M2HB and M85 Machine Guns.

Reference:

Type and No. - Final Draft Letter Requirement Date - 30 May 1975 Authority - PM, TRADE

Description/Justification:

Currently there is no widely available BFA for the M2 Heavy Barrel Caliber .50 Machine Gun nor for the M85 Caliber .50 Machine Gun. Neither is there a current Caliber .50 blank round of ammunition. There is in existence a small quantity of caliber .50 blank ammunition which was loaded about 1942. Most of this ammunition is in poor condition and the rest is judged unserviceable (Code E). Components for this ammunition are unavailable and obsolete and the design is inadequate for reliable performance, especially in the M85 Machine Gun. Thus there is no way to simulate the firing of these weapons in the field training environ- ment. As a result, two of the primary anti-personnel/anti-light vehicle/ anti-air weapons cannot be employed in tactical training. Given the requirement to use the weapons in engagement simulation systems such as REALTRAIN and MILES, a WESS is urgently required to provide a signature from the position of the firing weapon; the BFA will serve as that WESS for the caliber .50 machine guns. As part of the Marksmanship Laser System, the BFA will contribute to significant annual savings in real estate required for range firing.

Engineering Status:

1, BFA's for the M2HB weapon have been built and used with success in training at Ft. Benning and Ft. Knox. Earlier efforts in Canada and at TACOM, Warren, Michigan, with similarly designed BFA's have apparently been at least partially successful although no documentation of these test results has been located. Also since these BFA's were tested with the existing old, obsolete ammunition the performance may not be representative of the results to be obtained with newly prepared ammunition.

28 ■■3

2. BFA's for both M85 and M2HB are available in Europe from Dynamite-Nobel. These devices require a special, full profile, blank round which is produced and sold by Dynamite-Nobel. Performance characteristics of these BFA's are unknown.

3. Preliminary investigations of M2HB and M85 mechanism dynamics indicate that the M85 requires approximately 65% more energy than the M2HB to cycle the weapon and that the probability of product improving the BFA for the M85 is \/ery low unless product improvement of ammunition is undertaken simultaneously.

4. Given that BFA's are to be made readily available for both M2HB and M85 weapons and that a common blank round of ammunition is to be used in both weapons, it may be concluded from item 3 above that an improved round of ammunition must be based on the energy requirements of the M85 mechanism. Once the improved round of ammunition and BFA are available for the M85 it appears that improvement of the BFA for the M2HB can be based on the existing Ft. Benning units.

5. The most critical problem in improving these BFA's will be to insure through analysis and testing that sufficient energy is transferred to the weapon mechanism for reliable function without risking damage or excessive wear in the weapon mechanism caused by overstressing the various components.

6. An equally critical problem is caused by the requirement for the round to feed reliably through both the M2HB straight pull feed mechanism and the M85 push through feed system. At present it appears that the blank round will have to have a full profile configuration closely approximating the shape of the ball round.

Scope of Program:

RDT&E FY 77 FY 78 FY 79 Total Prog

M85 BFA 126K 126K 20K 272K

M2HB BFA 126K 126K 20K 272K

Ammunition See attached estimate of ammunition costs

Total RDT&E 252K 252K 40K 544K (Less Ammunition)

Procurement:

Procurement costs cannot be estimated in detail until analysis of the weapon/ammunition interface is completed.

Procurement quantities will be commensurate with the Basis of Issue which includes:

29

a. One device for each three (3) caliber .50 machine guns, M85 and M2HB, authorized by TOE/MTOE plus 10% float authorization (envisioned CTA as an inclusion).

b. Additional BFA authorization for M85 and for M2HB:

40 each* - USAARMS 10 each - USAFAS

20 each - USAIS 5 each - ACC

* Each type weapon, i.e., 40 for M85 plus 40 for M2HB

Basis for Cost Estimates:

Based on $40,000 per man year.

a. M85 BFA Product Improvement (PI):

Team Leader 3/4 man year $30,000

Analyst 1/4 man year $10,000

Mechanical Engr 1 man year $40,000

Engineering Tech* 1.5 man year $52,500

(* $35,000 per man year)

Total Direct Labor $132,500

Task 1 - Initial Phase

(1) Analyze M85 mechanism to determine safe limits of impulse at end of barrel.

(2) Design improved Ft. Benning type blank firing attachment.

(3) Design improved blank round configuration suitable for M85 feeding.

(4) At FA, design improved blank round based on required impulse and configuration, (1) and (3) above.

(5) Fabricate BFA hardware, 5 units.

(6) At FA, initiate ammunition improvement.

(7) Test.

(8) Evaluate

30

Initial Phase Time and Cost (RIA):

Elapsed Time - 4% months

RIA Direct Labor - $5096.15 x 4.5 $22,932.68

Hardware, 5 BFA units - $1500 x 5 $ 7,500.00

Computer - $800 x 4.5 $ 3,600.00

Test Range - 20 days x $1000/day $20,000.00

Total Initial Phase $54,032.68

Task 2 - Secondary PI

(1) Design modified BFA.

(2) Fabricate modified BFA, 5 units.

(3) At FA, design modified blank ammunition.

(4) At FA, fabricate #1 sample lot of ammunition, 5,000 rounds with PI propel 1 ant.

(5) Test.

(6) Evaluate.

Secondary PI Phase Time and Cost (RIA):

Elapsed Time - Ah months



Computer - $800 x 4.5 $ 3,600.00


Total Secondary PI Phase $76,032.68

Task 3 - Final PI Phase

(1) Finalize BFA design

(2) Fabricate BFA's, 10 units

(3) At FA, Finalize ammunition design.

(4) At FA, fabricate #2 lot of ammunition, 62,000 rounds, PI round.

31

(5) Conduct safety acceptance test.

*(6) Conduct engineering test (ET).

*(7) Conduct operational test (OT).

(8) Evaluate.

(9) Type classify.

Final PI Phase Time and Cost (RIA):

Elapsed Time - 17 months

RIA Direct Labor - $5096.15 x 17 $86,634.55

Hardware, 10 BFA units - $1500 x 10 $15,000.00

Computer - $800 x 17 $13,600.00

Safety/Acceptance Test - 18 days x $1000/day $18,000.00

♦Engineering Test, 180 day duration, 60 days support on site at Ft. Benning $ 5,742.00

♦Operational Test, 75 day duration, 25 days support on site at Ft. Benning $ 2,392.50

Total Final PI Phase $141,369.05

Total M85 BFA Product Improvement Program $271,434.41

*PM-TRADE will provide all manpower, supervision, funding, and facilities to perform those tests to be conducted at Ft. Benning. SARRI-LS will provide on-site technical support as indicated.

b. M2HB BFA Product Improvement Program

Team Leader 3/4 man year $30,000

Analyst 1/4 man year $10,000

Mechanical Engr 1 man year $40,000

Engineering Tech 1.5 man year $52,500

Total Direct Labor $132,500

32

ii'i

.',\'rii-.*?j,:?iri^,t4;:iri't>^

Task 1 - Initial Phase

(1) Analyze M2HB mechanism to determine safe limits of impulse at end of barrel.

(2) Design muzzle cap tube blank firing attachment similar to Ft. Benning BFA to use ammunition being developed for M85 BFA.

(3) Fabricate BFA hardware, 5 units.

(4) Test.

(5) Evaluate.

Initial Phase Time and Cost (RIA):

Elapsed Time - 4% months


Hardware, 5 units - $1500 x 5 $ 7,500.00

Computer - $800 x 4.5 $ 3,600.00

Test Range - 20 days at $1000/day $20,000.00

Total Initial Phase $54,032.68

Task 2 - Secondary PI Phase

(1) Design modified BFA.

(2) Fabricate Modified BFA.

(3) Test.

(4) Evaluate.

Secondary PI Phase Time and Cost (RIA):

Elapsed Time 4% months



Computer - $800 x 4.5 $ 3,600.00


Total Secondary PI Phase $76,032.68

33

Task 3 - Final PI Phase

(1) Finalize BFA design.

(2) Fabricate BFA's, 10 units.

(3) Conduct Safety Acceptance Test.

*(4) Conduct Engineering Test (ET).

*(5) Conduct Operational Test (OT).

(6) Evaluate.

(7) Type classify.

Final PI Phase Time and Cost (RIA):

Elapsed time - 17 months

RIA Direct Labor - $5096.15 x 17 $86,634.55

Hardware, 10 BFA units - $1500 x 10 $15,000.00

Computer - $800 x 17 $13,600.00

Safety/Acceptance Test - 18 days x $1000/day $18,000.00

♦Engineering Test - 18 days duration, 60 days support on site at Ft. Benning $ 5,742.00

♦Operational Test, 75 days duration, 25 days support on site at Ft. Benning $ 2,392.50

Total Final PI Phase $141,369.05

Total M2HB BFA Development Program $271,434.41

*PM-TRADE will provide all manpower, supervision, funding, and facilities to perform these tests to be conducted at Ft. Benning. SARRI-LS will provide on-site technical support as indicated.

c. Caliber .50 Blank Ammunition Product Improvement Program

Task 1 - The Caliber .50 Blank Ammunition will be Product Improved at Frankford Arsenal to meet the requirements for a common round of blank ammunition for use in both the M85 and M2HB Machine Guns. A detailed breakdown of Time and Cost, prepared and validated at Frankford Arsenal, is attached.

34

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APPENDIX B

PHOTOGRAPHS

FIGURE

1 TEST SET-UP FORT CARSON BFA

II FORT CARSON BFA MOUNTED ON M2HB

III TEST SET-UP FORT BENNING BFA

IV FORT BENNING BFA MOUNTED ON M2HB

V BULGED MUZZLE CYCLINDER^ FT CARSON BFA^ 9900 ROUNDS

VI BARREL MUZZLE ERROSION AFTER 8731 ROUNDS

VII BARREL MUZZLE ERROSION AFTER 8731 ROUNDS

VIII BARREL MUZZLE ERROSION AFTER 1L281 ROUNDS

IX BARREL MUZZLE ERROSION AFTER 11^281 ROUNDS

X BARREL MUZZLE ERROSION AFTER 13,261 ROUNDS

XI PRESSURE TEST SET-UP FORT CARSON BFA

XII PRESSURE TEST SET-UP FORT BENNING BFA

36

37

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APPENDIX C

INSPECTION REPORTS FOR

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59

APPENDIX D

AmUNITION PERFORMANCE

AND

SELECTION

60

ENDURANCE TEST AMMUNITION PERFORMANCE AND

SELECTION RATIONALE

The following three lots of blank ammunition were available in quantity for evaluating weapon life versus the Ft. Benning and Ft. Carson blank firing attachments (BFA).

1. Lot No. TW-L-18052

2. Lot No. LC-L-12035

3. Lot No. LC-L-95903

Endurance testing ammunition was selected from these lots on the basis of evaluation of time-displacement records.

Lot No. TW-L-18052 was selected for endurance testing with the Ft. Benning BFA. Time-displacement records indicated this was the only lot capable of functioning the M2HB Machine Gun with the Ft. Benning BFA at energy levels great enough to significantly affect weapon life. Unfortunately as the test progressed the performance of the remaining ammunition in this lot deteriorated drastically and the test had to be stopped after 4530 rounds of the scheduled 9900 rounds had been fired. Subsequent pressure-time readings taken in the muzzle cylinder using samples of remaining ammunition indicated poor combustion and \/ery low pressure being developed. This can only be attributed to advanced ammunition deterioration. It was noted that the ammunition boxes were not vapor sealed and there was extensive evidence of moisture intrusion and damage. The muzzle flame was observed to have a yellow color.

Ammunition Lot No LC-L-12035 was not vapor sealed but appeared to be relatively free from moisture damage. Both pressure tests and time displacement tests indicated fairly consistant performance but time displacement records showed energy levels considerably below the M33 ball round when using the Ft Benning BFA. Time displacement records indicated a good match to the M33 ball energy using the Ft Carson BFA. However, Lot No LC-L-95903 promised more consistant performance, as well as a satisfactory energy match and thus, was selected for endurance testing with the Ft Carson BFA.

Lot No LC-L-95903 was vapor packed and promised the most consistant performance of the three lots of ammunition. As stated above, it was, therefore, selected for endurance testing with the Ft Carson BFA. Unfor- tunately, time-displacement tests indicated that energy levels with the Ft Benning BFA were only about 70 - 75 percent of the M33 Ball round energy. While the weapon operated fairly consistantly at this low energy

61

level, the reduced velocities and accellerations negated the value of an endurance test conducted with this ammunition. The muzzle flame had a brilliant white color.

62

i'S.

MUZZLE CYLINDER PRESSURES

Blank Firing Attachment Ft Benning Ammunition: Lot No. LC-L- 12035 Shot No. Peak Pressure Pulse Duration (Sec) BFA No

1 3450 .032 2C 2 4250 .032 2C 3 3200 .030 2C 4 3820 .033 2C

Average 3680 Maximum 4250 Minimum 3200 Range 1050

Ammunition: Lot No. TW-L- 18052 5 2800 . 040 2C 6 450 .022 2C 7 2370 .039 2C 8 2450 .040 2C 9 2350 .038 2C

10 2170 \ .036 2C 11 1630 .044 2C 12 1590 ■r . 044 2C


Ammunition: Lot No. LC-L- 12035 13 3700 .040 2C

Ammunition: T40 Lot No LC -L-95903 1 5180 .025 2C 2 7050 .024 2C 3 5200 .023 2C 4 9300 .027 2C 5 9400 .025 2C 6 8600 .026 2C


63

<iS

MUZZLE CYLINDER PRESSURES

Blank Firing Atti achrr lent Ft Carson Ammunition: Lot No. LC-L-12035 Shot No. 1 Peak : Pressure Pulse Duration (Sec) BFA No

13A 3530 .042 lA 14 4310 .040 lA 15 7500 .041 • lA 16 5000 .042 lA 17 5590 .042 lA 18 5000 .035 lA


Ammunition: Lot No. TW-L-18052 19 6400 .040 lA 20 6350 .040 lA 21 6580 .042 lA 22 5600 .046 lA 23 7590 .050 lA 24 5030 .060 lA 25 6250 .036 lA 26 8120 .042 lA 11 5200 .040 lA


Aiimiunition: T40 Lot No. LC-L-95903 1 5190 .032 lA 2 8200 .032 lA 3 8100 .026 lA 4 8450 .030 lA 5 8375 .030 lA


64

Cf

DISTRIBUTION LIST

AGENCY COPIES

Project Manager for Training Devices 2 US Army Materiel Development and Readiness Command ATTN: DRCPM-TND Ft Benning, GA 31905

Commander 1 US Army Materiel Development and Readiness Command ATTN: DRCRD-JW, Mr. T. E. Cosgrove 5001 Eisenhower Avenue Alexandria, VA 22333

Commander 12 Defense Documentation Center Cameron Station, Bldg 5 Alexandria, VA 22314

President - . 2 US Army Infantry Board ATTN: ATZB-IB-WT Ft Benning, GA 31905

Commandant 2 US Army Infantry School ATTN: ATSH-I-V-P ^ Ft Benning, GA 31905

Commander 2 US Army Training and Doctrine Command ATTN: ATCD-TB Ft Monroe, VA 23651

1 1

10 2

Cormiander Rock Island Arsenal ATTN: SARRI-L ATTN: SARRI-LS ATTN: SARRI-LS-C ATTN: SARRI-LP-Library Rock Island, IL 61201

Commander Frankford Arsenal ATTN: SARFA-MDS-S (Mr. Donnard) Philadelphis, PA 19137

65

AGENCY

Commander US Army Armament Command Rock Island, IL 61201 ATTN ATTN ATTN

DRSAR-RD DRSAR-RDG DRSAR-ASI

COPIES

Conmander US Army Test and Evaluation Command ATTN: DRSTE-AR Aberdeen Proving Ground, MD 21005

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M2HB CALIBER - DTIC · 2015-05-26 · BLANK FIRING ATTACHMENTS .«. ' ... caliber .50 Machine Guns. In response to this need for a WESS, BFA to be used on the M2HB Machine Gun were